Electrical outlet boxes



p 3, 1955 G. M. WHELAN 2,717,715

ELECTRICAL OUTLET BOXES Filed April 24, 1953 1 1 ogogoyc olololololu 0 I I t i Q LLQLJLMOLLI o I; l 0 I404 INVENTOR. 6502 GE M lA/HELAN BY K7 United States Patent ELECTRICAL OUTLET BOXES George M. Whelan, Bothell, Wash.

Application April 24, 1953, Serial No. 350,977

2 Claims. (Cl. 2203.94)

This invention relates to outlet boxes as used for the installation of electrical devices, such as switches, sockets, receptacles and the like in residences, stores, shops and various other types of buildings. More particularly, the invention has reference to the provision of novel parts from which outlet boxes may be easily and readily assembled on the job to accommodate one or a plurality of electrical devices as may be desired or required for use at any particular location.

It is the primary object of the present invention to provide an elongated member of channel form that is divided into a succession of easily separable box units by interrupted cuts formed in the walls of said member; each unit, as thus defined, being pre-formed with the required knock outs, screw holes, and the like, for the entry of pipes, wires, cables, and for attachment of end plates and electrical fixtures, and the said units being separable from the elongated member for the formation of single, double, or triple unit boxes, or in greater numbers of units if such should be desired.

More specifically stated, the present invention resides in the details of construction and in the combination of parts embodied by the present invention, and particularly in the details of the elongated member of channel form from which ,the body portions of outlet boxes of any desired number of units may be made.

In accomplishing the above mentioned and other objects of the present invention, I have provided the improved details of construction, the preferred forms of which are illustrated in the accompanying drawings, wherein:

Fig. 1 is a front elevation of an elongated member of channel form as pre-formed and divided by interrupted cuts, transversely thereof, into a succession of box forming units.

Fig. 2 is a perspective view of a box member, comprising a succession of attached units, as separated from the channel member for the making of a plural unit outlet box.

Fig. 3 is a perspective view of an end plate as provided for use with the present box units.

Fig. 4 is a front view of a single unit outlet box as equipped at its opposite sides with closure plates of the kind shown in Fig. 3.

Fig. 5 is a triple unit box member as separated from the elongated member of channel form.

Referring more in detail to the drawings:

In accordance with the objects of the present invention, I provide, as in Fig. 1, an elongated member 6 of that particular channel form best shown in Fig. 2, and I divide it by means of evenly spaced and transversely directed cuts 8 into a succession of easily separable box forming units, each of which units is identical in dimensions and details of formation to the others. This elongated member 6, is formed from a single piece of sheet metal, of suitable kind and gauge, that is so bent as to provide a back wall 11, and opposite edge flanges 12 and 13, each of which flanges has an inwardly turned longiice tudinal edge portion 14. The flanges 12 and 13 are gradually curved into the back wall 11, as shown at 15 in Fig. 2, and also the inwardly turned portions 14 merge into the flanges 12 and 13 in gradually curved bends as seen at 1.6.

It is desirable that the dimensions of the box forming units shall correspond to standards already established for outlet boxes; therefore, in the forming of the present channel member, the back wall 11 thereof is made approximately four inches across, and the flanges 12 and 13 about two inches across. The inturned edge portions 14 of the flanges are approximately one-half inch across. The transverse cuts that are formed in the walls of the channel member to define the box forming units are spaced approximately one and thirteen-sixteenths inches apart. The transversely directed cuts, designated by reference numeral 3 are interrupted at certain definite locations so as to retain the box units in rigid connection until the cuts are completed. It is to be noted that each cut 8 is interrupted at the corners of the channel member, leaving quite short uncut portions as at 21. Also, the cuts 8 as formed across the back wall of the channel member are interrupted at half-way points to leave the unit connecting portions as designated at 24.

Formed centrally in the back wall and flange portions of each box unit, as defined between the cuts 8, are partially detached circular knock-outs 25. Also, the inturned edge portions of the flanges are formed with threaded screw holes 26 properly located for the securement of the electrical devices that are to be used in the outlet boxes. It is noted also that the upper and lower walls of each box forming unit are formed with screw holes as at 30, for the reception of screws used in the attachment of side closure plates.

Side closure plates 34 for the box units are made in accordance with the showing of the plate in Fig. 3. Each plate is of such size that it can be received within an open side of a box forming unit. As shown best in Fig. 3, each plate 34 has a continuous inturned flange 36 extending along its back, top and lower edge; these flanges being punched with holes 38 to register with holes 30 in the box units.

In assembling the side plates 34 with a box forming unit, they are applied thereto as seen in Fig. 4, each with its flange portions 36 disposed within the enclosing walls of the unit; the parts then being secured together by the application of screws 40, as seen in Fig. 4, through registered holes 30 and 38 in the parts that are overlapped.

The advantage in the provision of box forming parts as herein shown resides in the fact that the workman can assemble outlet boxes of any desired number of box units on the job. Upon his determining how many units are required for any particular location, he can, by means of a hack saw, sever the desired number of units from the channel member 10, merely cutting through the connecting portions 21 and 24. In this way, outlet boxes of one unit, as seen in Fig. 4 or of three units as in Fig. 5, or in more units can be readily provided. Then a pair of opposite plates 34 are applied thereto, and a box of the desired number of units is ready for installation.

Holes 42 in the back wall of the units are provided for passage of nails or screws and also the side plates may be provided with knock-outs 45 as shown in Fig. 3.

The manner of using such outlet boxes, in so far as the application thereto of circuit wires, cables and devices such as switches, sockets, etc., is concerned, is exactly like that of present day outlet boxes.

Having thus described my invention, what I claim as new therein, and desire to secure by Letters Patent, is:

1. An elongated housing, open along its forward side; said housing being formed from a single strip of sheetmetai, bent substantially to channel form, with a back Wall, top and bottom Walls and flanges turned toward each other along the forward edges of the top and bottom walls; said back Wall merging into the top and bottom Walls in gradually rounded bends, and said top and bottom Walls merging into said flanges in gradually rounded bends, and said housing being formed across the main Wall portions thereof and across said flanges with aligned cuts defining a succession of relatively short separable box sections; said sections of the housing being joined only by the incut portions between aligned cuts at the rounded corner forming portions of the housing.

2. A housing as in claim 1 wherein each of the said References Cited in the file of this patent UNlTED STATES PATENTS Kling Oct. 5, 1909 Dennis June 9, 1925 Elliott et a1. Feb. 6, 1945 Schenk Jan. 15, 1952 

